RETALT_TPS design and manufacturing

The present document discusses the development of a new trowelable Thermal Protection System (TPS), able of being mixed, applied and cured directly onto the vehicle structure, with the aim to fulfill the requirements of the thermal properties for the re-usable launch vehicle studied in the Retro Propulsion Landing Technology (RETALT) project. During the development of this TPS, several formula optimizations were made to improve or eliminate cracks in the char surface, increase char stiffness, rheological adjustments, and adhesion improvement to different substrates. The most promising material developed is composed by cork and epoxy resin, together with a set of rheological and thermal resistance additives, that makes it possible to be applied with a spatula, while at the same time it is able to withstand the demanding environmental conditions during atmospheric reentry. In terms of thermal properties, the developed material has a higher thermal conductivity than the current P50 TPS commercialized by Amorim Cork Composites (ACC), but it has a better behavior when exposed to flame conditions. It is expected that the absence of cracks improves its structure and resistance to demanding conditions. The development work included a detailed study of the composition and processes required for the development of a TPS material, which were evaluated by several types of flame characterization tests and thermal properties analysis.

Cost, Draping, Material and Partitioning Optimization of a Composite Rail Vehicle Structure

This study proposes a novel methodology to combine topology optimization and ply draping simulation to partition composite structures, improve structural performance, select materials, and enable more accurate representations of cost- and weight-efficient manufacturable designs. The proposed methodology is applied to a structure as a case study to verify that the methodology is effective. One design concept is created by subjecting the structure to a kinematic ply draping simulation to inform the partitioning of the structure, improve drapability and performance, and reduce structural defects. A second design concept is created that assumes that plies are draped over the entire structural geometry, forming an integral design. The two design concepts’ topologies are subsequently optimized to specify ideal material and ply geometries to minimize mass and reduce costs. The results indicate that the partitioned structure has a 19% lower mass and 15% lower material costs than the integral design. The two designs produced with the new methodology are also compared against two control designs created to emulate previously published methodologies that have not incorporated ply draping simulations. This demonstrates that neglecting the effects of ply draping produces topology optimization solutions that under-predict the mass of a structure by 26% and costs by 38%.

Investigation of Adhesive Joining Strategies for the Application of a Multi-Material Light Rail Vehicle

To meet the high demand for lightweight energy-efficient and safe structures for transport applications, a current state-of-the-art light rail vehicle structure is under development that adopts a multi-material design strategy. This strategy creates the need for advanced multi-material joining technologies. The compatibility of the adhesive with a wide range of material types and the possibility of joining multi-material structures is also a key advantage to its success. In this paper, the feasibility of using either epoxy or polyurethane adhesive joining techniques applied to the multi-material vehicle structure is investigated. Importantly, consideration is given to the effect of variation in bond thickness for both families of structural adhesives. Multi-material adhesively bonded single lap joints with different adhesives of controlled bond thicknesses were manufactured and tested in order to experimentally assess the shear strength and stiffness. The torsional stiffness and natural frequency of the vehicle were modelled using a global two-dimensional finite element model (FEM) with different adhesive properties, and the obtained vehicle performances were further explained by the coupon-level experimental tests. The results showed that the vehicle using polyurethane adhesive with a target bond thickness of 1.0 mm allowed for optimal modal frequency and weight reduction.

Research of Vibrations of an Armoured Personnel Carrier Hull with FE Implementation

Modern wheeled armoured vehicles can perform a variety of tasks, making the development of weapon systems that can be safely and effectively integrated with the vehicle structure an area of interest. Due to the cost of implementing new models, it is more economical to test potential configurations using numerical methods, such as the finite element method. The numerical model has been validated to confirm the reliability of the obtained results. Modal tests were also performed using four configurations to identify the frequency and mode shape of natural vibrations occurring within the support structure. In an experimental setting, hull vibrations were forced using the modal hammer testing method. The modal assurance criterion (MAC) and the authors’ procedure were used to confirm the experimental and numerical test results. Additional testing in the form of impact loads was carried out for turret-containing structures. Structural strain at indicated points and forces transmitted by brackets to the bottom of the hull were compared.

The influence of suspension nonlinearities on fatigue assessment of vehicle structure

Load spectrums for the fatigue analysis were created using suspension responses generated in a simulation of vehicle and suspension vertical dynamics nonlinear model for different conditions of vehicle use. The next stage presented was the use of finite element method and analysis of obtained stresses with its transformation to a set of cycles that are used in the determination of fatigue characteristics. The qualitative and quantitative analysis of the stresses field in the vehicle structure and suspension elements was done and later the influence of suspension responses on the fatigue assessment for most loaded parts of suspension and vehicle structure. Lastly conclusions were drawn from the results describing qualitative and quantitative influence of different road class and load conditions on fatigue assessment of vehicle structure and suspension components. Conclusion on the proposed and used methodology also was drawn.

Reversed-torsion-type crush energy absorption structure and its inexpensive partial-heating torsion manufacturing method based on origami engineering

Current vehicle energy absorbers face two problems during a collision in that there is only a 70% collapse in length and there is a high initial peak load. These problems arise because the presently used energy-absorbing column is primitive from the point of view of origami. We developed a column called the Reversed Spiral Origami Structure (RSO), which solves the above two problems. However, in the case of existing technology of the RSO, the molding cost of hydroforming is too expensive for application to a real vehicle structure. We therefore conceive a new structure, named the Reversed Torsion Origami Structure (RTO), which has excellent energy absorption in simulation. We can thus develop a manufacturing system for the RTO cheaply. Excellent results are obtained in a physical experiment. The RTO can replace conventional energy absorbers and is expected to be widely used in not only automobile structures but also building structures.

Energy Absorption Characteristics of Passenger Car With Origami Structure

In the crash collision, the vehicle energy absorbers play an important role in the energy absorbed performance. Current vehicle energy absorbers have two defects during collision, such as only 70 % collapsed in its length and high initial peak load. It is because present energy absorbed column is the most primitive from the point of Origami structure. We developed the column so called Reversed Spiral Origami Structure; RSO which solves these 2 defects. However, for RSO, the manufacturing cost of hydroforming in the existing technology is too expensive to be applied in real vehicle structure. To address the problems, we have developed a new molding method called “Partial-heating torsion molding method”. And we have developed RTO (Reversed Torsion Origami Structure) by this new molding method at a very low cost. We show this RTO also solves the two defects of the present vehicle absorbers by not only simulation but also experiments. This structure is possible to replace conventional energy absorbers and it is expected to be widely used such as not only in automobile structures but also in building ones.

Experimental Study of Rigid and Flexible Tandem Wing for Micro Aerial Vehicle

Unmanned aerial vehicle is becoming increasingly popular each year. Now, aeronautical researchers are focusing on size minimization of unmanned aerial vehicle, especially drone and micro aerial vehicle. The lift coefficient of micro aerial vehicle has wing dimension of 12 cm and mass of less than 7 g. In the present study, with the aid of 3D printer, polylactic acid material was used to develop the micro aerial vehicle structure for tandem wing arrangement. The materials for rigid wing skin and flexible wing skin were laminating film and latex membrane, respectively. The present work elaborates the lift coefficient profiles on rigid wing skin and flexible wing skin at wing flapping frequency of 11 Hz, three different Reynolds numbers of 14000, 19000 and 24000, and five different angles of attacks between 0° and 50°. According to the results obtained, the lift coefficient decreased as the Reynolds number increased. The lift coefficient increased up to 9 as the angle of attack increased from 0° to 50° at the Reynolds number of 14000 for flexible wing skin. The results also showed that the lift coefficient of flexible wing skin was higher than that of rigid wing skin at the attack angle of10° and below, except for the Reynolds number of 14000.